Advances in Vehicle Design To Ruth Advances in Vehicle Design by John Fenton Professional Engineering Publishing Professional Engineering Publishing Limited London and Bury St Edmunds, UK First published 1999 This publication is copyright under the Berne Convention and the International Copyright Convention All rights reserved Apart from any fair dealing for the purpose of private study, research, criticism, or review, as permitted under the Copyright Designs and Patents Act 1988, no part may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, electrical, chemical, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owners Unlicensed multiple copying of this publication is illegal Inquiries should be addressed to: The Publishing Editor, Mechanical Engineering Publications Limited, Northgate Avenue, Bury St Edmunds, Suffolk, IP32 6B W, UK © John Fenton ISBN 86058 181 A CIP catalogue record for this book is available from the British Library The publishers are not responsible for any statement made in this publication Data, discussion, and conclusions developed by the Author are for information only and are not intended for use without independent substantiating investigation on the part of the potential users Opinions expressed are those of the Author and are not necessarily those of the Institution of Mechanical Engineers or its publishers Printed and bound in Great Britain by St Edmundsbury Press Limted, Suffolk, UK CONTENTS vii Preface Chapter 1: Materials and construction advances Steel durability and structural efficiency Vigorous development of light alloys Hybrid metal/plastic systems Recycled PET, and prime PBT, for sun-roof parts 10 Material property charts and performance indices 13 Design for self-pierce riveting Chapter 2: Structure and safety 20 24 27 31 Structure analysis for interior noise Preparing for statutory pedestrian protection Design for the disabled Adaptive restraint technologies Chapter 3: Powertrain/chassis systems 36 45 47 52 58 62 Powertrains: the next stage? Constant-pressure cycle: the future for diesels? Valve arrangements for enhanced engine efficiency Trends in transmission design The mechanics of roll-over Suspension and steering linkage analysis Chapter 4: Electrical and electronic systems 70 76 79 81 84 90 Automotive electronics maturity Navigation system advances Digital circuits for computation Proprietary control system advances Hybrid drive prospects Automation of handling tests Chapter 5: Vehicle development 96 Mercedes A-class 102 Ford Focus 108 Land Rover Freelander 112 Project Thrust SSC Chapter 6: Systems development: powertrain/chassis 118 Engine developments 122 Engine induction systems 124 Refinement and reduced emissions 128 Drive and steer systems 133 Suspension development 139 Braking systems Chapter 7: System developments: body structure/systems 144 Structural systems 144 Controlled collapse 145 Body shell integrity 147 Chassis/body shell elements 151 Car body systems 151 Occupant restraint 155 Doors, windows and panels 159 Trim and fittings 161 Aerodynamics and weight saving 163 CV systems 163 CV chassis-cab configuration 164 Cab/body fittings 168 Advanced bus/ambulance design 173 References 175 Index Preface This lite'rature survey is aimed at providing the vehicle design engineer with an update in vehicle and body systems The author has scanned the considerable output of technical presentations during 1997- to extract and distil developing technologies of particular import to the working designer The easily digestible presentation, with unusually high dependence on diagrammatic presentation, continues the popular style used for the original handbooks that were compiled by the author, and published by Professional Engineering Publishing These are listed on the Related Titles page overleaf Advances in Vehicle Design serves both as an update to the earlier volumes and as a stand-alone volume The referenced leads provided in the text are intended to help designers and engineers from whatever background discipline Widespread availability of computing power to designers and engineers has created the possibility of considerably shortening the lead-times between design conception and prototype manufacture Much of the material covered here will assist in establishing predictive techniques Advances in Vehicle Design is an update of vehicle and body systems design in that it provides readers with an insight into analytical methods given in a wide variety of published sources such as; technical journals, conference papers, and proceedings of engineering institutions, for which a comprehensive list of references is provided The analyses are therefore not necessarily fully developed or rigorously evaluated Recourse to the original references is necessary particularly in order to understand the limiting assumptions on which the analyses are based Much of the analytical work is centred around impending legislation and, where this is quoted in the text, it is for illustration only and it is, of course, important to examine the latest statutes in the locality concerned The list of references given at the end of the volume is a key element of the publication, providing where possible a link to the original publication source Where the original publication is not available in bookshops, many of the sources can be found in libraries such as those of the Institution of Mechanical Engineers, London, or the Motor Industry Research Association, in Nuneaton, UK,as well as the BritishLibrary.Othersimilar respositories of techincal information should be able to provide a selection of original source material Where the source is a company announcement of techniques and systems, names, but not addresses, of the companies/consultancies are given Most operate internationally and have different national locations, best found by enquiry in the country concerned For the patent reviews in chapters six and seven, full specifications can be purchased from The Patent Office, Cardiff Road, Newport, NP91RH, UK JOHNFENTON Related Titles Title Editor/Author Multi-Body Dynamics HRahnejat Gasoline Engine Analysis J Fenton Handbook of Automotive Body Construction J Fenton and Design Analysis Cranes - Design, Practice and Maintenance J Verschoof Handbook of Automotive Body Systems Design J Fenton Handbook of Automotive Powertrain and J Fenton Chassis Design Vehicle Handling Dynamics J Ellis Handbook of Vehicle Design Analysis J Fenton Automotive Braking: - Recent Developments D Barton Brakes and Friction Materials G A Harper Automotive Engineer Monthly Magazine W Kimberley Journal of Automotive Engineering (IMechE Proceedings Part D) ISBN/ISSN 80058 122 85298 634 86058 073 86058 130 86058 067 X 86058 075 0 85298 885 0 85298 963 86058 131 1860581277 0307/6490 0954/4070 For full details of all Professional Engineering Publications please contact: Sales Department Professional Engineering Publishing Nothgate Avenue Bury St Edmunds IP326BW UK Telephone: +44 (0)1284 763 277 Fax: +44(0)1284718693 E-mail: sales@imeche.org.uk Chapter 1: Materials and construction advances The considerable comeback made by the steel industry in restating its case for structural superiority over the light alloys, and the ever moving goalposts of developing aluminium and polymer composites, open this chapter The re-emergence of hybrid metal/plastic structures is also discussed as well as the creation of reinforced plastics with recycled-polymer matrices The move to material property charts which lead to the creation of performance indices is next examined and the chapter concludes with the efforts to make self-pierce riveting a viable alternative to conventional welded joints in body construction 164 VEHICLE DESIGN Fig 62b: Concept truck suspension and drive detail slender, deep sidemembers have brackets extending outwards, beyond the inner road-wheels, to give as wide a spring-base as possible Concept has become production in the case of the important breakthrough which has been made by Dennis Specialist Vehicles It involves a dedicated space-frame chassis for the new Rapier fire-appliance vehicle, Fig 63 Dramatic improvement in ride and handling is claimed over the conventional ladder-frame and leaf-spring layout — with the availability of a more rigid frame to mount a suspension of greater sophistication Over a tonne of weight has been pared from the conventional structure and a low deck height has also been achieved — with a particularly low-slung engine The latter has permitted the cab to be mounted 250 mm lower than usual, removing the need for entry steps The entire crew cab tilts in one piece and the lightweight body is made in corrugated aluminium alloy sheet over an extruded section frame — incorporating water tanks made from plastic Substantial coil springs suspend both front and rear wheels and, at the rear, wheels are independently suspended by a double wishbone system Body roll, under 0.6 g lateral acceleration, has been reduced to 3.1 degrees compared with 8.5 degrees for a comparable conventional vehicle Cab/body fittings Recent patent specifications reveal a number of the detailed improvements which have been made to truck systems An example is the suspended cab-tilt pivot design in Fig 64 Here a truck cab suspension which is sympathetic to the cab-tilt system, without causing discomfort to the occupants, is proposed The cab itself hinges on the uppermost pivot of the Fig 63: Dennis Rapier space-frame chassis Fig 64: Soft-mounted cab tilt by ERF, in Patent GB2188884A BODY STRUCTURE DEVELOPMENT Fig 65: Return-load tanker by Clayton Commercials (GB2298830 A) Fig 66: Variable cube body by York Trailers in Patent GB2198091A Fig 67: Air-bag system van-cube system by JR Cramp, covered in Parent GB2299311A 165 mechanism shown while beneath it a second pivot forms the scissor linkage of the suspension mechanism — based on a rubber 'doughnut' compression spring and hydraulic damper A return-load tanker is the subject of the interesting patented design in Fig 65 The classic difficulty is tackled here in the operation of tankers and bulkers, not being able to fill the tanks with a return load, which might contaminate the principal product carried According to the claimants, existing efforts to build dual purpose vehicles, carrying both dry goods and flow products on flat-topped tankers, have involved overweight structures Here the lower portion of the vehicle, for flow products, comprises typically two large cylindrical vessels which form substantial structural members of the vehicle Cradles around the vessels support the upper floor for carrying dry goods as well as proving a mounting for the running gear of the vehicle A number of attempts have been made to produce 'variable cube' bodies A means of, literally, raising the roof of this van body is proposed by the design in Fig 66 An air-inflatable bag is positioned between the body wall and a lever which compresses the bag Inflation of the bag moves the lever and pulls cables to operate the roof-raising device Shown in this example mounted to the step of a step-frame trailer, cables from the pulleys shown pass beneath the chassis to operate jacks in the body corner posts Another proposal also concerns raising the roof with airbags Previous efforts have made been made to lift the roof of curtain-sided vehicle by an amount corresponding to the depth of the projecting border which covers the curtain tracks, to allow easier loading of tall cargo items Because such efforts have thus far involved cumbersome mechanisms, the design of Fig 67 is aimed to simplify the approach by the use of airbags A scissor linkage is associated with the air-bag, positioned at the top front/rear corners of the vehicle body The compressed air supply would normally be reservoir tanks fed by the vehicle's air-compressor and air-lines would run through the roof support uprights Improved cargo retention is the object of the design in Fig 68 Problems of complexity, and associated proneness to wear, of existing cargo retention devices for goods vehicles can be reduced by the adoption of this mechanism in the design shown Channels on each side of the deck anchor bracing 166 VEHICLE DESIGN beams, by means of a socket beneath each channel The beams are either stowed within the channels or tilted upwards to brace the load The beam is released from the load-retention position by raising it towards the vertical and then displacing it axially, from where it is pivoted to the stowed position The interior of the beam encloses a restraining strap which is withdrawn to secure the cargo, the strap retracting into the beam automatically when not in use The object of the Fig 69 design is to provide an easy-access curtainsider Means to avoid complex slider mechanisms for the body-side support pillars of a curtainsider are provided in the arrangement shown In order to move the pillars to ease sideaccess of bulky loads, the pillars are mounted on a hinged linkage Hinged corner-posts for a curtainsider are covered by the design of Fig 70 The need to provide front-corner posts, of curtain sided CV bodies, which are faired in plan view to achieve aerodynamic efficiency, results in a dead space behind the section profile when loading the container body by fork truck from the side In order to avoid a secondary loading operation, to enable pallets to fill the dead space, hinged post sections are suggested When the flaps are in their closed position the side-curtain is wrapped around them and secured in socket catches prior to tensioning Considerably reduced effort to open and close the side-curtains of a curtainsider truck-body is claimed in the interesting roller arrangement of Fig 71 The roller track section is profiled to allow tilting of the rollers as they roll along the track The rollers comprise ball bearings with convex sectioned tyres of hard plastic over their outer races This set-up overcomes the problem with conventional systems of Fig 71: Improved curtam-sider by Montracon covered by Patent GB2291095A Fig 68: Improved cargo retention system suggested by Boalloy Industries, covered in Patent GB2301067A Fig 69: Easy-access curtainsider by Cartwright Freight Systems (GB 2185715A) Fig 70: M &G Tankers & Trailers have suggested hinged post sections, in Patent proposal, GB2293144A BODY STRUCTURE DEVELOPMENT Fig 72: Simplified curtainsider support post in Patent GB2209712A by John J Cameron Fig 73: Compact sliding door gear by Bedwas Bodyworks, in Patent GB2203184A Fig 74: Tail-lift in door by Tidd Strongbox, covered in Patent GB2207112A Fig 75: Upper-deck levelling achieved by the UK Lift Company, covered in Patent GB2299791A 167 binding of the rollers when the curtain is displaced sideways by the operator during pulling Each hanger bracket is supported by two or more rollers A simplified support post for curtainsider CV bodies is proposed in the design of Fig 71 The cumbersome toggle linkage provided at the lower end of the column is dispensed with The upper end slides on the cant rail, as normal practice, but the lower end locks to the side-rave, by means of a simple spigot linkage shown here A compact sliding door gear system is offered in the design of Fig 73 The difficulty is overcome here of accommodating two ISO pallets lengthwise across the platform of a goods vehicle — within the maximum legal vehicle width and the clearance envelope of the door gear This design uses a 'master' plug-and-slide door suspended from a carriage and swing-arm assembly Tail-lift in a door is the result of the ingenious design of Fig 74 A tail-lift platform which doubles as a part-closure to prevent cold air fallout from refrigerated vehicles is raised and lowered by carriages in the rear doors of the body in this design The body comprises a number of refrigerated compartments and a separate folding canopy can temporarily close the upper ones Levelling a lifting deck is the object of the Fig 75 design Existing mechanisms used to raise the decks of goods vehicle bodies, to achieve two-tier stowage of the payload, suffer from the moving deck becoming unlevel as it is raised on jacks In this design movement of the deck is synchronized by the interaction of two toothed racks mounted on the body and toothed wheels mounted on the moving deck Connection of the wheels by shaft or endless chain ensures the level movement of the deck regardless of ram motions Folding catwalk rail is covered by the design of Fig 76 Added safety for road tanker operators is provided by this pivoting catwalk rail When access to the top of the tanker is not required the rail lays flat across the catwalk to prevent ingress by unwanted intruders When legitimate access is required hydraulic rams raise the rail to an upright position while interlocks ensure the vehicle's brakes stay on, in this position Perhaps the ultimate in cab access is offered by the Fig 77 design Overcoming the ingress and exit restrictions for driver and operators of crew-cabbed 168 VEHICLE DESIGN commercial vehicles is the objective, particularly suited to vehicles with front overhead loaders The driver's seat and controls are centrally mounted while those for the crew are mounted above and behind, on either side of the cab and over the wheel housings Doors of 1.9 metres in height open inwardly to prevent pavement obstruction The floor is inclined upwards at the front and level at the back and provides cross cab access ahead of the engine compartment Advanced bus/ambulance design Rethinking the ambulance configuration is behind the design of Fig 78 Emergency transport of accident victims in heavy traffic was the impetus behind an interesting vehicle to handle urban emergencies discussed at a recent Autotech congress Authors Da Silva and Miranda of Lisbon Technical University explained that the key design factor was provision of an efficient life condition support for the patient in a vehicle with exceptional traffic mobility That involved a highly compact layout yet a comfortable posture and space for medical assistance to the patient in transit The short journeys inherent in the duties of the vehicle make it an attractive proposition for electric traction and in the proposed design the patient would be positioned above the battery container Twin rear wheels would be mounted on an oscillating axle, the 'banking' of which would be Fig 77: Short-haul ambulance controlled by the driver, or 'rider' in a semi motorcycle situation, sitting behind the single steering front wheel of the vehicle Retractable outrigger wheels would also be used to provide cornering stability in less dense traffic conditions Translucent panelling around the patient compartment would reduce the claustrophobic effect as would careful colour selection for the interior A joint venture between MAN and Voith has resulted in the NL 202 DE low floor concept city bus, Fig 79, designed to carry 98 passengers at a maximum speed of 70 km/h No steps are involved at any of the entrances, which lead directly to a completely level deck height of between 317 to 340 mm The rear-mounted horizontally positioned diesel engine allows fitment of a bench seat at the rear of the bus; it drives a generator with only electrical connection Fig 76: Pivoting catwalk rail proposed by Safewalk Railings in Patent GB 2203390A Fig 77: Easy-access cab by Britannia Trucks (GB2297951A) BODY STRUCTURE DEVELOPMENT Fig 79a: NL 202 DE concept MAN bus with propulsion system detail below 169 to the Voith transverse-flux wheel motors, which drive the wheels through two-stage hub-reduction gear sets The diesel is rated at 127 kW and the generator at 135 kW; the controller is of the IGBT converter type and also developed by Voith It provides a differential action to the wheel motors on cornering Permanent magnet synchronous wheelmotors are rated at 57 kW and have a maximum speed of 2500 rev/min; see Table in Fig 79a The bus is 12 metres long and has water-cooling for its generator, converters and wheel motors As well as providing virtually jerk-free acceleration, the drive system is seen by MAN as providing the possibility of fourwheel drive on future articulated buses to improve traction and stability in slippery road conditions The term 'transverse flux motor' refers to the means used to guide the magnetic flux in the stator; this is new to inverter-supplied PM types and involves a novel collector configuration Double-sided magnetic force generation is also new and involves a patented double air gap construction having high idling inductances and force densities up to 120 kNm/m2, with relatively low losses A new control process permits operation of the motor in a field-weakening type mode, in spite of PM excitation The generator is almost identical in concept but involves no field weakening Each has concentric construction of permanent magnets, rotor/stator soft-iron elements and stator winding; see Fig 79a Armature elements are U-shaped cut stripwound core sections, embedded in the ring-shaped supporting structures of inner and outer stators Each core surrounds the windings and forms a stator pole with its cut surfaces facing the rotor The latter is pot-shaped and positioned between poles of the outer and inner stators In the stator pole region it comprises magnet and soft iron element while in the winding region a ring of GRP serves as the connecting TFM wheel motor Power 57 kW 735 rev./min Rated speed Approx max speed 2,500 rev/min Max fundamental frequency of stator ,350 Hz 740 Nm Rated torque ,050 Nm Approx max torque Approx torque conversion 1:3 Power/weight ratio 1.8kg/kW TFM generator 135 kW ,750 rev./min 2,400 rev./min 740 Nm 740 Nm 0.9 kg/kW VEHICLE DESIGN element The inverters supply the motors with sinusoidal currents and voltages until the nominal operating point is reached; operating frequency is 10 kHz In field-weakening mode the induced voltage exceeds intermediate circuit voltage and only square wave voltages are supplied to the motor Power output then remains constant and the operating frequency equals the fundamental motor frequency A large speed ratio, 1.5:1, is thus possible An electric city-bus designed for low drag is seen in the Centre concept midibus from Capoco Design, Fig 80 It is intended to show the practicality of 'available now' electric drive technology for city centre operation The 7.3 metre long vehicle would operate at up to 40 kph and have a range of 40 miles Energy consumption is reduced by the vehicle's drag coefficient of just 0.31 and low rolling-resistance tyres of modest section profile A lightweight structure comprises mechanically fastened aluminium Fig 81: Aero-style luggage rack designed by Ikarus covered by Patent GB2209140A \) EGR electromagnetic control valve 2) Electronic control unit 3) Accelerator position reinforcement 4) Brake pedal switch 5) Clutch pedal switch 6) EGR valve 7) Thermostarter 8) Thermostarter feed valve 9) Instrumented injector 10) Water temperature sensor 11) Engine speed sensor 12) Vehicle speed sensor 13) Water in fuel sensor 14) Water flow and temperature sensor 15) Engine stalling solenoid 16) Engine advance adjustment 17) Fuel flow and temperature adjustment 18) Injection pump Fig 79 b: Performance characteristic and power-unit environmental control system BODY STRUCTURE DEVELOPMENT 171 alloy extrusions covered by a single-piece roof moulding In full standee form up to 56 passengers can be carried and deck height is just 290 mm Shown also in Fig 80 is the economical packaging of batteries and drive motor, with near vertical drive axis Width of the vehicle is 2380 mm and height 2550 m, on a 4050 mm wheelbase An aero-style bus saloon assembly follows from modular elements used in this patented roof liner and luggage rack assembly, Fig 81, for touring coaches The arrangement involves zed-shaped brackets screwed to the roof frame which secure headlining, ventilating ducts and luggage shelves The shelf elements incorporate a profiled channel, for housing light fittings, which is closed by a snap-fit translucent cover Fig 80: Capoco Centra electric bus This page intentionally left blank 173 References Chapter 1 Sears, K., Automotive engineering: strategic overview, Steel Times, Vol No.l, 1997 Matthews and Davies, Precoated steels development for the automotive industry, Proc I.Mech.E., Vol 211., Part D, 1997 Rink and Pugh, The perfect couple — metal/plastic hybrids making effective use of composites, IBCAM Conference, 1997 Merrifield, R., Instrument panel structural concepts which integrate functions utilizing injection moulded plastic components, Paper C524/120/97, Autotech Congress, 1997 Ashby, M., Material Property Charts, Performances Indices, Section 4, Material Selection and Design,20th edition , ASM International, 1997 Chapter Bass et al, A system for simulating structural intrusion, Proc I.Mech.E., Vol 211., Part D, 1997 Yim and Lee, Design optimization of the pillar joint structures using equivalent beam modelling technique, SAE Paper 971544, part of P-308 Hardy, M., Automotive modelling and NVH seminar, Proc.I.Mech.E., 1997 Hargreaves, J., I Mech.E Vehicle noise and vibration conference, 1998 Lawrence and Hardy, Development and use of pedestrian impactors to reduce the injury potential of cars, paper C524/049/97, Autotech 1997 Coleman and Harrow, Car design for all, IMechE seminar , 1997 Delphi Automotive, Adaptive restraint technologies, Vehicle Engineer, December 1998 Chapter Evans and Blaszczyk, A comparative study of the performance and exhaust emissions of a spark ignition engine fuelled by natural gas and gasoline, Proc.I.Mech.E., Vol 211, Part D, 1997 Perkins and Penny, Design options and performance characteristics for 0.25-0.3 litre/cylinder HSDI diesel engines, Euro 4challenge: future technology and systems, IMechE Seminar, 1997 Sadler et al., Optimization of the combustion system for a direct-injection gasoline engine using a high speed in-cylinder sampling valve, Euro 4challenge: future technology and systems, I.Mech.E Seminar, 1997 Zhou and Qian, Development of a modified diesel engine cycle, Proc I.Mech.E., Vol 212, Part D, 1998 Cains et al., High dilution combustion through axial and barrel swirl, I.Mech.E Seminar Publication: Automotive Engines and Powertrains, 1997 Bassett et al., A simple two-state late intake valve closing mechanism, Proc IMechE, Vol 211, Part D, 1997 Woods and Brown, Flow area of multiple poppet valves, Proc IMechE, Vol 210, Part D, 1996 Ohashi et al, Honda's speed all clutch to clutch automatic transmission, SAE Paper 980819 Abo et al., Development of a metal belt-drive CVT incorporating a torque converter for use with 2-litre class engines, SAE Paper 980823 10 Ahluwalia et al, The new high torque NVT-750 manual transaxle, SAE Paper 980828 11 Turner and Kelly, A transmission for all seasons, Advanced vehicle transmission and powertrain conference, I.Mech.E., 1997 12 1998 SAE software based on book: Gillespie, G, Fundamentals of vehicle design, SAE, 1992 13 Gadola and Cambiaghi, MMGB: a computerbased approach to racing car suspension design, ATA, Vol 47., no 6/7., 1994 14 Ellis, J, Vehicle handling dynamics, Mechanical Engineering Publications, 1994 15 Potter et al, Assessing 'road-friendliness': a review, Proc I.Mech.E., Vol 211., Part D, 1997 Chapter la Bodoni-Bird, C, What can seamless electromechanical vehicles learn from Nature?, 96C001, 1b Miyata et al, Engine control by ion density analysis, 96C003 Ic Pinkos and Shtarkman, Electronically controlled smart materials in active suspension systems, 96C004 1d Hatanaka and Noro, New approach for intelligent steering system development, 96C007 le Milburn, S, Integration of advanced functions into electric drivetrains, 96C050 from the bound volume of proceedings of the 1996 Convergence Transportation Electronics Association conference 2a Kuragaki et al, An adaptive cruise control using wheel torque management technique, 980606 174 VEHICLE DESIGN 2b Olbrich et al., Light radar sensor and control unit for adaptive cruise control, 980607 from the bound volume of proceedings of the ITS Advanced controls and vehicle navigation systems seminar at the 1998 SAE Congress Bolton, W., Essential mathematics for engineering, Heinemann Jones et al., HYZEM — a joint approach towards understanding hybrid vehicle introduction into Europe, Proceedings of the IMechE Combustion engines and hybrid vehicles conference, 1998 Friedmann et al., Development and application of map-controlled drive management for a BMW parallel hybrid vehicle, SAE Special Publication SP1331, 1998 Nagasaka et al., Development of the hybrid/battery ECU for the Toyota Hybrid System, SAE Special Publication SP1331, 1998 Saito et al., Super capacitor for energy recycling hybrid vehicle, Convergence 96 proceedings Origuchi et al., Development of a lithium-ion battery system for EVs, SAE paper 970238 Chapter Bowsher , G, Braking and traction at supersonic speeds, Special Vehicle Engineer, January 1998 Chapter SAE papers 870147/8 I.Mech.E Autotech paper C427/40/108 Proc I.MechE., Vol 206, Aerodynamics of Grand Prix cars I.Mech.E Autotech Paper C427/6/032 INDEX Index Access to door hardware 156 Acoustic model of vehicle cabin 21 Adaptive restraint technologies 31 Advanced car and truck engines 120 Advanced suspension linkage 133 Aero-style luggage rack 170 Aerodynamics 161 Aged 50+ coupe 27 Airbag module as horn-push 152 A12 concept car Alternative injector installations 41 Alternative valvetrain layouts 42 Anti-dive motor cycle suspension 137 Ashland Pliogrip fast-cure adhesive ASI passenger-side low-mount airbag 31 Auto-adjust towbar 142 Auto-steer for trailer 131 Automatic cruise control, ACC 78 Automatic drive selection 129 Automation of handling tests 90 Automotive electronics maturity 70 B Bayer Durethan BKV polymer composite BMW for its rear suspension, 850i coupe 133 BMW parallel hybrid drive 85 Body shell integrity 145 Body structure and systems, Ford Focus 105 Body systems of Freelander 109 Body-in-white of M-B A-class 98 Bonnet latch 159 Boot-stowage of roof 158 Bosch Motronic MED management system 81 Brake apportioning for solo or coupled mode 141 Braking system of M-B A-class 101 Braking systems 139 Bus and ambulance design 168 Cabin acoustic model 22 Calliper and disk assembly, Thrust SSC 114 Cambridge Consultants composite structures 148 Capoco Centre electric bus 170 Car body systems 151 Cargo retention system 166 175 Chassis systems 133 Chassis/body shell elements 147 Child safety seat 151 Chrysler China car Clock enable circuit 80 CNG's advantage over gasoline 39 Collins CMC scotch-yoke engine 127 Compact door latch 158 Compact sliding door gear 167 Compliance representation 64 Constant-pres sure cycle 121 Constant pressure cycle piston modification 122 Constant-pressure cycle: the future for diesels? 45 Control Blade rear suspension 104 Control strategies for CVT 56 Control strategy for 4-wheel steer 138 Controlled -collapse trim 151, 160 Controlled collapse 144 Controlling restraint deployment 33 Conventional and electric drivetrain 75 Cosworth Engineering's MBA engine 118 Crash severity sensing 31 Cross-bolting of main-bearing caps 118 CV chassis-cab configuration 163 CV systems 163 CV-joint packaging 131 CVT engine torque curve matching 56 CVT for 2-litre engined vehicles 53 D DAF concept truck 163 Dallara MMGB suspension design software 63 Delphi E-STEER electronic steering 82 Dennis Rapier space-frame chassis 164 Design for the disabled 27 Diesel engine with oil-cushioned piston 45 Digital circuits for computation 79 Direct injection gasoline 43 Door seals 155 Doors, windows and panels 155 Double-level floor of Mercedes A-class 97 Drive and steer systems 128 Drive strategy for influencing factors 57 Driverless taxi 29 Drivetrain control 75 E Easy-access cab 168 Easy-access curtainsider 166 176 VEHICLE DESIGN Easy-assemble brake booster 142 Easy-change CV-UJ assembly 130 Electric double-layer capacitors (EDLCs) 88 Electro-rheological magnetic (ERM) fluids 72 Electromagnetic braking 141 Electromagnetic valve actuation 122 Electronic brake actuation system 139 Electronic control of electric steering 73 Electronic Stability Programme on Focus 103 Emissions of small HSDI diesels 40 Energy storage initiatives 88 Engine developments 118 Engine force balancer for motorcycle 126 Engine refinement 124 Engine temperature management 121 Engine-coolant airflow 132 Equilibrium lateral acceleration 59 European 13 Mode test 39 Exhaust fixing 161 Height-adjust for trailer coupling 142 High activity, homogeneous charge concept 47 High-torque manual transmission 54 Honda automatic transmission 53 Honda intelligent steering system 74 Hybrid drive prospects 84 Hydraulically sprung connecting rod 45 Ideal cycle efficiency 46 Intake valve disablement 47 Integrated air/fuel induction system 122 Integrated engine/transmission 43 Integrated latch/lock system by Bosch 157 Integration of clutch servo actuator parts 142 Interior noise analysis 20 Interior sound pressure distribution 23 Intrusion simulation mechanism 17 Ion current response 70 K Fail-safe brake actuator 141 Fatigue life of valve gear 125 Fatigue performance of Fastriv system 14 Fibre-optic light division system 161 Filtering diesel particulates 127 Fluid-actuated anti-roll control 136 Flywheel battery 128 Flywheel to crankshaft connection 126 FMVSS impact energy absorption levels Footwell deformation in vehicle impact 16 Ford Focus 102 Freer moving bogie suspension 136 Front and rear wheels, Thrust SSC 112 Front brake, Thrust SSC 115 Fuel delivery system 161 Fuel injection rethought 122 Fuel stratification 44 Fuji Industies ELCAPA hybrid vehicle 89 G Gas storage requirement 39 Gear train schematics 52 H Handling software example 60 Head rest adjuster 154 Headway sensor design 77 Kyoto tram 30 L Land Rover Freelander 108 Late intake valve closing 48 Lateral acceleration of tractor/trailer 61 LD-SRIM composite panel construction 162 Leg injuries 33 Light-alloys development Liquified natural gas (LNG) 40 LNG-powered ERF truck 39 Logic circuits 79 Lotus Elan structure 149 Lotus Engineering Jewel Project engine 120 Low-cost supercharging 122 M Magnesium Association Design Award MAN diesel pollution control 126 MAN and Voith NL 202 DE low floor city bus 168 Material property charts/performance indices 10 Mazda punt structure 150 Mechanical systems on Freelander 110 Mechanics of roll-over 58 Mercedes A-class 96 Metal/plastic systems Millbrook VTEC facility 38 Mobility for all 27 INDEX MSC/NASTRAN 19 Multi input/output gearbox 129 Multi-node suspension model 62 Multiple valve arrangements 49 N Navigation system advances 76 Necked hub member 138 New Venture Gear NVT-750 gearbox 55 Nissan CVT configuration 54 Nissan CVT for 2-litre cars 53 Non-stick front forks 136 o Occupant protection in side impact 146 Occupant restraint 151 Occupant sensing 31 Optimized re-charge strategy 86 Optimizing unsprung mass with wheel travel 133 Parallel hybrid drive mechanism 85 Part-load control by late intake valve closing 48 Particle orientation in Theological fluid 72 Particle size analysis 37 Particulate size distribution 37 Passive Anti-Theft System (PATS) 107 Pedestrian protection device 160 Pedestrian protection in impact 24 PEM fuel cell, natural gas fuelled 89 Personal Productivity info-technologies 81 Pillar to rail joint stiffness 18 Plastic structural beam Plenum and port throttles 119 Plunge joint 130 Poppet valve effective area comparison 50 Poppet valve half-angles/radius-ratios 51 Porshe suspension sub-frame 148 Power interaction diagram for hybrid drive 86 Powertrain on Ford Focus 104 Powertrains: the next stage? 36 Primary safety system of M-B A-class 99 Production hybrid-drive control system 87 Proprietary control system advances 81 Pyrotechnic actuated venting 33 Q Quicker catalyst light-up 127 177 R RACD damper unit 73 Racing clutch 129 Rapid-actuation diff-lock 129 Rear brake, Thrust SSC 116 Recycled PET, and prime PBT, for sun-roof parts Reduced-emission systems 124 Refinement of individual systems, Ford Focus 102 Return-load tanker 165 Road guidance for drowsy drivers 77 Road traffic NOx emissions 38 Road-friendliness, a current review 66 Roll effects 65 Roll reactions on suspended vehicle 58 Roll response to step input 59 Rover Asymmetric Combustion Enhancement 47 Sachs variable valve timing 125 Sarich 2-stroke 124 Scania turbo-compound diesel 120 Seamless electro-mechanical vehicle 70 Seat adjustment mechanism 153 Seat of Mercedes 300 SL 153 Seat-belt pretensioners 151 Secondary safety systems 96 Self-pierce riveting 13 Self-steering in forward and reverse 138 Set-speed down-hill braking 142 Shopping ferry 30 Short-haul taxi 28 Side airbag within seat back 152 Side impact protection structure 145 Sidemember construction novelty 147 Sill and quarter panel joint 146 Simplified level sensing 160 Sliding door drive 159 Smart materials for suspension control 71 Soft-mounted cab tilt 164 Specific stiffness property chart 11 Specific strength property chart 12 Speeding engine warm-up 127 Split tailgate 155 Steel durability and structural efficiency Steer fight in braking 135 Steering assist mechanism 82 Steering column immobilizer 137 Steering robot 91 178 VEHICLE DESIGN Steering system on Freelander 111 Steering-castor adjustment 137 Storing swirl energy 122 Strengthening a convertible body 148 Structural-coloured fibre has body trim potential Structural design in polymer composites Structural systems 144 Structure of Freelander 108 Supercapacitors for hybrid drive 88 Super-element in FEA 20 Sure-fire gear engagement 129 Suspension and steering linkage analysis 62 Suspension compliance conflict 135 Suspension compliance work of John Ellis 64 Suspension development 133 Suspension geometry control 135 Suspension supports of M-B A-class 100 Swivel pin bearing pre-stressing 137 Synthetic urban drive cycle 84 Systems integration effect on sensors 70 Tail-lift in door 167 Taxis and people movers 28 TEC mobility system 81 Textron Fastriv system 13 Through-bolt and monoblock configurations 43 Thrust SSC land-speed jet car 112 Tiller steering 137 Torque reaction system for steering robot 92 Torque roll axis engine mounts on Focus 107 Toyota Hybrid System 87 Transient roll-over 59 Transmission design trends 52 Transverse spring composite suspension 133 Tribus guided vehicle system 128 Trim and fittings 159 TRL knee joint model 24 TRL leg-form impactor 25 Truck and bus emissions 38 Tuned suspension mounts on Focus 107 Turbocharger waste-gate control 121 Two-dimensional suspension analysis 64 Two-stage energy absorption 144 u ULSAB body shell Urban rickshaw 27 Valve arrangements for engine efficiency 47 Variable cube body 165 Variable geometry engine intake 125 Variable valve timing 125 Vehicle body FEM 23 Visualization of in-cylinder flow 44 VVT for Rover K-series 124 w Wheeled battle-tank 132 Winder mechanism 156 Zero-offset geometry 103 ZFCFT20CVT 57 ... applications (below) Fig 25: Riveting module sizes (right) Fig 26: Fatigue performance (above) STANDARD "C" FRAME SIZES (FOR 4Omm DAYLIGHT) APPROXIMATE FRAME DEPTH ARM DEPTH WEIGHT(KG) "G"(mm) "G'"(mm).. .Advances in Vehicle Design To Ruth Advances in Vehicle Design by John Fenton Professional Engineering Publishing Professional Engineering Publishing Limited London and... Dusseldorf is used in a new design of sliding roof incorporating a built -in Venetian blind, Fig 14 The PBT slats of the blind can be adjusted to deflect cooling air into the vehicle in hot weather